Pneumatically actuated assembly apparatus and method of assembly

ABSTRACT

An assembly apparatus is provided for assembling two members, such as, for example a hose and a hose clamp. The assembly apparatus includes a base having first and second independently extendible members. A dispenser, joined to a third independently extendible member, is operatively connected to the base. A pneumatic or hydraulic control system actuates each of the first, second and third independently extendible members, such as pneumatic cylinders, to position the dispenser relative to the hose and hose clamp. Generally, the first and second independently extendible members extend along a first axis while the third independently extendible member extends along a second axis and the second axis is generally orthogonal to the first axis. The present invention joins the hose and hose clamp without the need to distort the generally smooth outer surface of the hose. A method of assembling the two members is also disclosed.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional application60/438,439 filed on Jan. 8, 2003, which is incorporated herein byreference in its entirety.

FIELD OF INVENTION

The present invention relates generally to a pneumatically actuatedassembly apparatus and method for assembling a hose and hose clamp and,more particularly, to an apparatus and method of assembly that appliesadhesive to an outer surface of a hose, positions a hose clamp about thehose and mates the hose and hose clamp together.

BACKGROUND OF THE INVENTION

High volume manufacturing environments are constantly demanding easier,more cost effective manufacturing techniques to improve their assemblyoperations. One such area demanding improvement is the automotive fieldemploying radiator hose and hose clamp assemblies. In mass productionenvironments, it is preferable for the hose clamp to be secured to anouter surface of the radiator hose prior to insertion on an assemblyline into an engine. Traditionally, to facilitate an effectiveconnection of the hose and hose clamp the typically smooth outer surfaceof the hose is distorted, roughened or chemically etched to create aminimally porous outer surface. The porous outer surface absorbs anadhesive to facilitate a more effective connection between the hose andthe hose clamp. An automated process that quickly and easily joins thehose and hose clamp without the need for distorting the outer surface ofthe hose and minimizes the amount of manual intervention from anoperator is greatly desired in the mass production environment.

Further, most complex machinery used to automate a typically manualprocess are large and usually unreliable. Accordingly, there exists aneed for a compact, reliable and self-controlled assembly apparatus thatcan simply assemble two members such as a radiator hose and a hoseclamp.

BRIEF SUMMARY OF THE INVENTION

An assembly apparatus is provided for joining first and second members.The assembly apparatus includes a base having first and secondindependently extendible members. A dispenser is operatively connectedto the base and also joined to a third independently extendible member.Each of the independently extendible members is actuated by a controlsystem to position the dispenser relative to the first and secondmembers.

A method of assembling the first and second members is also disclosed.The first step includes providing an apparatus having a firstindependently extendible member, a second independently extendiblemember, a third independently extendible member, and a dispenseroperatively connected to the third independently extendible member.Next, the first and second members to be assembled are inserted intoassembly fixtures. The first independently extendible member is extendedto orient the dispenser about the first member. Next, an adhesive isdispensed from the dispenser to an outer surface of the first member.The third independently extendible member is retracted to align thefirst and second members. The second independently extendible member isextended and compression is applied to join the first and secondmembers.

Among other advantages, the inventive assembly apparatus is compact andreadily configurable to repetitively assemble two members, such as ahose and hose clamp. Another advantage is that the assembly apparatusefficiently assembles a hose and hose clamp with a minimal amount ofmanual intervention and without the need to distort the smooth outersurface of the hose.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and inventive aspects of the present invention will becomemore apparent upon reading the following detailed description, claims,and drawings, of which the following is a brief description:

FIG. 1 is a plan view of an assembly apparatus, according to anembodiment of the present invention, with a cover removed for clarity.

FIG. 2 is a plan view of the assembly apparatus of FIG. 1 having a firstindependently extendible member extended.

FIG. 3 is a plan view of the assembly apparatus of FIG. 2 having asecond independently extendible member also extended.

FIG. 4 is an end view of the assembly apparatus having a thirdindependently extendible member extended and the dispenser removed forclarity.

FIG. 5 is an end view of the assembly apparatus with the thirdindependently extendible member retraced and the dispenser removed forclarity.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1-5, an assembly apparatus 100 according to anembodiment of the present invention is shown. A plan view of assemblyapparatus 100 is illustrated in FIGS. 1-3 with a cover removed forclarity. FIG. 1 illustrates assembly apparatus 100 in a home position.Assembly apparatus 100 includes side plate 31 and first and second endplates 16, 25 to define a base for apparatus 100. Each of the plates 16,25 and 31 are fastened together using bolts or the like. Assemblyapparatus 100 also includes a shaft 23 fastened to both the first andsecond end plates 16, 25 at opposite ends to further define the base.

Within the base are first and second independently extendible members 24and 22 generally extendible along the X-axis shown in FIGS. 1-3. Firstindependently extendible member 24 is threaded at one end and attachedto first end plate 16. The opposite end is attached to a first plate 12.A threaded rod 14 extends between first plate 12 and a fixed block 21.Threaded rod 14 also extends through first end plate 16. A support rod15 is threaded to first plate 12 to join first plate 12 to a firstintermediate plate 17.

Second independently extendible member 22 is also threaded at one endand attached to fixed block 21. Fixed block 21 also receives shaft 23that joins the first and second end plates 16, 25, as described above,to define the base. Further, the opposite end of second independentlyextendible member 22 is connected to shaft 13. Shaft 13, while attachedat one end to second independently extendible member 22, is attached atthe opposite end to block 10 with a fastener such as a bolt or the like.Further, the same fastener utilized to join shaft 13 to block 10 is alsoutilized to join block 10 to a mandril 6. Shaft 13 also extends throughfirst plate 12 and first end plate 16. First plate 12 includes at leastone bearing member 11 slidably received over shaft 13. Bearing member 11is preferably an oil-impregnated sleeve bearing that is press-fit intofirst plate 12.

In the present invention, a second assembly fixture 7 is designed toaccommodate a second member (not shown), such as a hose clamp. In theembodiment shown in FIGS. 4 and 5, an inner profiled surface 7 a ofsecond assembly fixture 7 is shaped to accommodate the profile of atypical adjustable hose clamp. A first assembly fixture (not shown)receives a first member (also not shown), such as a hose. The preferredfunction of assembly apparatus 100 is to join the first and secondmembers. In an exemplary embodiment, the first assembly fixture isgenerally not aligned with the second assembly fixture 7. Instead, thefirst assembly fixture is positioned along a Y-axis vertically offsetfrom the second assembly fixture 7. The offset positioning of theassembly fixtures facilitates the easy manual insertion of the hose andhose clamp into the fixtures by an operator.

Referring to FIGS. 4-5, second assembly fixture 7 is connected to adispenser 8 and a third independently extendible member 1. A fixed plate5 is fastened to block 10 by a bolt or the like. Shafts 2 are receivedin holes of fixed plate 5 and are joined to a second plate 3 by a pairof set screws or the like. Second plate 3, shafts 2 and second assemblyfixture 7 are extendible in relation to fixed plate 5 by thirdindependently extendible member 1 and third independently extendiblemember 1 is operatively connected to the base. Fixed plate 5 includes atleast one bearing member 4 slidably received over each of shafts 2.Bearing member 4 is preferably an oil-impregnated sleeve bearing that ispress-fit into fixed plate 5.

Attached to second plate 3 is dispenser 8. Second plate 3 includes aretaining mechanism 27 to retain dispenser 8. However, dispenser 8 mayalso be attached by fasteners such as set screws, bolts or the like. Itis contemplated by the present invention that the attachment ofdispenser 8 to second plate 3 permits adjustment of dispenser 8vertically along the Y-axis and also in other directions desired by oneskilled in the art. In an embodiment, dispenser 8 dispenses a smallamount of adhesive or glue onto an outer surface of the first member(e.g. a hose). However, the dispenser may dispense any material asdeemed necessary by an operator of assembly apparatus 100. In FIGS. 4-5,dispenser 8 is removed for clarity.

In an embodiment of the present invention, first, second and thirdindependently extendible members 24, 22, 1 are pneumatically orhydraulically operated. Therefore, a control system 30, as describedherein, includes a means of distributing fluid power between a source ofpressurized fluid and first, second and third independently extendiblemembers 24, 22, 1. However, it will be appreciated that other extendibledevices, such as a motor driven screw mechanism, may be used in place offirst, second and third independently extendible members 24, 22, 1without departing from the scope of the present invention. In such aconfiguration, control system 30 may include specific devices, such as aprogrammable logic controller (PLC), for controlling operation of theextendible members 24, 22 and 1.

Referring to FIGS. 1-3, assembly apparatus 100 is provided with a mainport 32 to which the source of pressurized fluid, such as compressedair, is connected. Main port 32 is provided in direct communication withfirst, second and third three-way valves 33, 28 and 34, which aregenerally, but not necessarily, pneumatically operated to simplifyoperation of assembly apparatus 100. For clarity, the conduits (e.g.flexible tubing or hose) provided between port 32 and valves 33, 28 and34 are not illustrated in FIGS. 1-3. Further, an exemplary embodiment ofthe present invention includes a manifold 29. Manifold 29 is positionedbetween the fluid supply at main port 32 and each of the valves 33, 28and 34 to regulate the supply of fluids to each of the valves 33, 28 and34.

Although the described control system 30 is configured with fluid poweroperated valves to distribute a pressurized fluid through assemblyapparatus 100, it is not necessarily limited thereto. Alternatively,other suitable fluid power distribution devices, such aselectromechanically operated valves, are also within the scope of thisinvention.

Operation of the inventive assembly apparatus 100 will be describedherein with reference to FIGS. 1-5. Provided a source of air isconnected to assembly apparatus 100 at main port 32 and the first andsecond members (e.g. a hose and hose clamp) are manually inserted intothe first assembly fixture and second assembly fixture 7 respectively,the operating sequence is initiated by an operator selectively supplyinga signal or pulse of air to first three-way valve 33. The operator mayinitiate this pulse of air by simultaneously depressing a pair ofpneumatically operated safety switches, or by any other suitable meansknown in the art.

Upon receipt of a signal or pulse of air, first three-way valve 33shifts and supplies air to first independently extendible member 24.Regarding first independently extendible member 24, the receipt of aircauses it to extend first plate 12 away from first end plate 16 alongthe X-axis, as illustrated in FIG. 2. The distance first independentlyextendible member 24 extends first plate 12 is selectively variable byadjusting the position of a first collar 18 along support rod 15. Asshown in FIG. 2, extension of first independently extendible member 24and first plate 12 stops when first collar 18 abuts first intermediateplate 17. Once first independently extendible member 24 is fullyextended, dispenser 8 is positioned or oriented appropriately about thefirst member for dispersing an adhesive.

When first collar 18 abuts first intermediate plate 17, a limit switchactuator 35 is actuated and depresses a first two-way limit switch 36.An air signal is sent from first limit switch 36 through control system30 to an external dispensing system (not shown). The dispensing systemreceives the signal or pulse of air and begins its own sequence totransfer glue to dispenser 8. In an embodiment of the present invention,dispenser 8 applies a bead of glue or adhesive to an outer surface ofthe first member (e.g. hose). An exemplary glue is a cyanoacrylate orthe like commerically available from Loctite® located at 2455Featherstone Road, Auburn Hills, Mich. 48326. Additionally, Loctite®also supplies glue dispensing systems such as Single Function Controller98023, which may be provided in communication with dispenser 8 tofacilitate application of the adhesive. However, the present inventionmay incorporate any type of dispensing system to dispense adhesive orany other type of material.

Once the adhesive bead is applied to the outer surface of the firstmember or hose, the dispensing system sends a signal or air pulse backto control system 30 to second three-way air valve 28. Upon receipt ofthe signal or pulse of air, three-way air valve 28 shifts and suppliesair to third independently extendible member 1. Regarding thirdindependently extendible member 1, the receipt of air causes it toretract and move second plate 3 away from fixed plate 5 along theY-axis, as illustrated in FIGS. 4-5. Further, second assembly fixture 7having the hose clamp is also moved vertically upward along the Y-axis.As shown in FIG. 5, retraction of third independently extendible member1 and second plate 3 stops when third independently extendible member 1fully retracts and depresses two-way limit switch 9. Limit switch 9sends a signal or air pulse to third three-way valve 34. When thirdindependently extendible member 1 is fully retracted the hose and hoseclamp are aligned.

The use of terms extend and retract are not intended to be limiting. Oneskilled in the art can practice features of the present inventionutilizing alternative retracting and extending orientations of theextendible members 24, 22 and 1.

Upon receipt of the signal or pulse of air, third three-way air valve 34shifts and supplies air to second independently extendible member 22.Regarding second independently extendible member 22, the receipt of aircauses it to extend and move block 10 away from plate 12 along theX-axis, as illustrated in FIG. 3. Further, dispenser 8 is moved awayfrom the hose and the hose clamp is positioned over the hose and gluebead. Also, the extension of second extendible member 22 inserts mandril6 into the hose and positions the hose clamp over the hose. As shown inFIG. 3, extension of second independently extendible member 22 and block10 stops when a second collar 19 abuts first end plate 16

When second collar 19 abuts first end plate 16, a second two-way limitswitch 38 is depressed. An air signal is sent from second limit switch38 to a pneumatic timer 37. Timer 37 initiates and will release an airsignal after a set amount of time. In an embodiment of the presentinvention, the preset amount of time is approximately 10 seconds topermit the adhesive to cure and the first and second members to beadhered together.

Also, when second collar 19 abuts first end plate 16, an air signal issent from second limit switch 38 to second valve 28. Second valve 28shifts from supplying air to retract third independently extendiblemember 1 to supplying air to extend third independently extendiblemember 1. The third independently extendible member extends and pressesthe second member or hose clamp onto the bead of adhesive, hose andmandril 6. Mandril 6 is received within the first member or hose toprevent collapse of the hose when subjected to compression from thethird independently extendible member 1. Third independently extendiblemember 1 will continue to compress the first and second members togetheruntil pneumatic timer 37 expires and sends an air signal.

Applying compression or downward force upon the first and second membersminimizes or eliminates the need, as described above in the Background,to distort the generally smooth outer surface of the hose. Instead, thepresent invention applies an appropriate amount of force to generate aneffective adherence between the hose and the hose clamp. An insufficientamount of force will result in an ineffective assembly of the twomembers. Further, force or compression above the appropriate amount willdistribute the adhesive and also result in an ineffective assembly ofthe two members.

Upon expiration of the preset amount of time, timer 37 sends the airsignal to first valve 33, second valve 28 and third valve 34. Further,timer 37 sends an air signal to a fourth valve 20. Fourth valve 20exhausts air from the third independently extendible member 1 andaccordingly, force or compression is no longer exerted upon the firstand second members. A delay is incorporated into first and third valves33, 34. Fourth valve 20 exhausts third independently extendible member 1and then first and third valves 33, 34 switch to retract first andsecond independently extendible members 24, 22. The delay prevents theretraction of first and second independently extendible members 24, 22from interfering with the assembled first and second member in the firstassembly fixture. Next, second valve 28 switches to extend thirdindependently extendible member 1. In this configuration, all items arereturned to their home positions, as shown in FIG. 1 and the operatingcycle is deemed complete. The joined first and second members may bemanually or automatically ejected or removed from the first assemblyfixture.

Although certain preferred embodiments of the present invention havebeen described, the invention is not limited to the illustrationsdescribed and shown herein, which are deemed to be merely illustrativeof the best modes of carrying out the invention. A person of ordinaryskill in the art will realize that certain modifications and variationswill come within the teachings of this invention and that suchvariations and modifications are within its spirit and the scope asdefined by the claims.

1. An assembly apparatus for joining first and second memberscomprising: a base including first and second independently extendiblemembers; a dispenser joined to a third independently extendible member,said third independently extendible member operatively connected to saidbase; and wherein said first, second and third independently extendiblemembers are actuated by a control system to position said dispenserrelative to the first and second members.
 2. The apparatus of claim 1,wherein said control system is a pneumatic control system.
 3. Theapparatus of claim 2, wherein said control system includes at least oneinlet port for connecting the assembly apparatus to a source ofcompressed air.
 4. The apparatus of claim 3, wherein said control systemincludes at least one valve for selectively routing air between saidinlet port and each of said first, second and third independentlyextendible members.
 5. The apparatus of claim 4, further including apneumatic timer operatively connected to said valve.
 6. The apparatus ofclaim 2, wherein said first, second and third independently extendiblemembers are pneumatic cylinders.
 7. The apparatus of claim 1, whereinsaid first and second independently extendible members are generallyextendible along a first axis and said third independently extendiblemember is generally extendible along a second axis, said second axisbeing generally orthogonal to said first axis.
 8. The apparatus of claim1, wherein said control system is a hydraulic control system.
 9. Theapparatus of claim 1, wherein said second independently extendiblemember includes a mandril and, when said second independently extendiblemember is extended, said mandril is received by the first member tofacilitate joining of the members.
 10. The apparatus of claim 1, furtherincluding assembly fixtures to receive the first and second members. 11.The apparatus of claim 1, wherein said dispenser expels an adhesive upona surface of one of the first or second members. 12.-18. (canceled)